Floor finish application system using applicator pad and matched floor finish composition

ABSTRACT

A system for the formation of a thick robust transparent floor finish layer from a high solids formulation with an applicator device utilizing micro fiber technology. A micro fiber applicator device can be configured to apply a sufficient amount of an aqueous high solids floor finish to obtain a thick robust finish layer in a single application. One system for applying the floor finish can comprise a source of aqueous floor finish and an applicator wand comprising an application nozzle and application surface. Application surface can comprise micro fiber technology in a pad structure comprising a reservoir foam and a micro fiber applicator surface.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of application Ser. No.10/794,429, filed Mar. 5, 2004, which is a continuation-in-part ofapplication Ser. No. 10/177,901, filed Jun. 19, 2002, which is acontinuation-in-part of application Ser. No. 09/992,195, filed Nov. 14,2001, now U.S. Pat. No. 6,695,516, and a continuation-in-part ofapplication Ser. No. 10/732,028, filed Dec. 9, 2003, now U.S. Pat. No.7,063,474, which is a continuation of application Ser. No. 09/992,195,filed Nov. 14, 2001, now U.S. Pat. No. 6,695,516. The presentapplication is also a continuation of application Ser. No. 10/986,474,filed Nov. 11, 2004.

FIELD OF THE INVENTION

The invention relates to a portable apparatus that can be used todistribute a high solids floor finish on a floor surface. The apparatusis adapted for high solids aqueous floor finish compositions that can bedistributed to form a single robust layer of floor finish in oneapplication on a resilient vinyl floor. In an embodiment, the systemincludes a backpack adapted for a single user, wand applicator having anapplication nozzle, an applicator pad, a high solids content aqueousfinish composition, and apparatus to meter the correct amounts of floorfinish.

BACKGROUND OF THE INVENTION

The application of aqueous floor finish compositions to institutionalfloor surfaces, in particular to resilient vinyl flooring, remainsdifficult problem for floor maintenance personnel. In the past floorfinishes have been applied using multiple applications of conventionalfloor finish compositions to build up a robust finish layer. Such manualapplications are often accomplished by pouring liquid floor finish ormetering liquid floor finish onto a surface and uniformly distributingthe liquid floor finish using a mop, weighted “T” bar, or otherapplication device. Such application techniques often result in anuneven application, undesirable flawed surface appearance, unnecessarylabor costs and often can result in insufficient thicknesses forcommercial flooring. We have found that mobile or portable apparatus forfloor maintenance are known. For the purpose of this application, we arenot interested in an apparatus adapted for of floor cleaning protocols.In the cleaning art, the mobile technology typically involves the use ofaqueous cleaners and rinses for removing soils, low solids floor finishcompositions and other undesirable materials from floor surfaces.

Conventional aqueous floor finish compositions are formulated in avariety of product types. The products vary with respect to the type ofmaterials combined in the formulations and with respect to the amount ofsolids found in the formulations. The use of high solids floor finishcompositions poses unique problems. Application technologies developedfor conventional low solids floor finish compositions are ofteninadequate when used in high solids applications. Further theconventional application techniques cannot take advantage of the uniqueproperties of high solids floor finish materials. Substantial need tohas arisen for improved methods and equipment that can be used inapplying high solids floor finish materials.

We're aware of the following patents generically related to floormaintenance technologies. Gewalt (U.S. Pat. No. 2,053,282), Thompson(U.S. Pat. No. 2,061,216), Payne (U.S. Pat. No. 2,731,656), Minerley(U.S. Pat. No. 2,875,463) and Cushing (U.S. Pat. No. 4,119,386) disclosean apparatus typically characterized in the prior art as “a fountainmop.” Such systems include typically a wand having mounted thereon, areservoir for an aqueous material that can be applied through a“fountain” and a mop head that can be used to distribute the aqueousmaterial. Similar to such fountain mops, Floyd (U.S. art. No.1,778,552), Burfield (U.S. Pat. No. 4,984,328) and Sloan (U.S. Pat. No.4,971,471) each teach a mop or brush head that includes a spray systemfor introducing an aqueous material into the head or on a floor.

One common configuration of a typical mobile floor cleaning system isthe portable or motor driven cleaning machine such as that shown inGirman et al. (U.S. Pat. No. 4,893,375) or Tipton (U.S. Pat. No.5,331,713) these apparatus are configured to sequentially apply cleaningmaterials to a floor, scrub the floor and then remove the cleaningmaterials for further operations.

Keppers, et al. U.S. Pat. No. 6,017,163, teaches a wheeled portablefloor finish distribution apparatus mounted on a wheeled cart using anapplicator nozzle, wand and distributor device to apply aqueous floorfinish compositions.

A brief review of these disclosures show that no system is availablethat is adapted for the convenient, efficient application of a liquidfloor finish over a large area floor using a portable cart system.Available applications systems are not adapted to take advantage of theunique properties of high solids floor finish compositions. The largerportable or motor driven systems prior art systems are adapted for theserial application and removal typically by vacuum systems of aqueousmaterials used to wash, rinse or maintain floor surfaces.

Conventional technologies are not truly adapted for a single userperforming the application of a single robust floor finish layer fromhigh solids materials. In large part the prior art is directed towardsportable systems that clean large areas of institutional flooring, butnot directed towards applying maintaining floor finish layers.

A substantial need exists for apparatus and methods adapted to theformation of a single robust floor finish layer by a single maintenanceindividual using high solids floor finish compositions.

BRIEF DISCUSSION OF THE INVENTION

The invention relates to a floor finish application system including asource of aqueous floor finish in fluid communication with an applicatorwand. The applicator wand includes a handle, metering apparatus for thehigh solids floor finish applicator nozzle, a distribution pad and,optionally, a high solids aqueous floor finish composition. In anembodiment, a distribution pad using microfiber technology is pairedwith a high solids aqueous floor finish to permit a single applicatorindividual to apply a single coat, thick, robust floor finish in asingle application or pass.

In an embodiment, the floor finish in a flexible container is placedinto a backpack housing. The flexible container can be equipped with aconnector that can couple to a conduit, which can be attached to theapplicator wand structure. The wand structure can include a conduitdirected to a floor finish applicator nozzle that can be used to meteran appropriate amount of the floor finish composition onto the resilientvinyl floor surface. A single conduit can couple to both the containerand the nozzle. The system can include a filter positioned to filter thefloor finish before or as it leaves the container. The wand structurealso includes an attached micro fiber pad that can be used to distributethe aqueous finish at an appropriate rate of application in anappropriate application amount for a single pass application of thethick floor finish layer.

For the purpose of this patent application, the term “resilient vinylflooring” refers to conventional commercial flooring materials commonlyfound in commercial establishments such as large retail stores.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a depiction of an embodiment of the portable application unitor back pack of the invention capable of containing the liquid finishmaterial preferably in the form of one or more flexible containers offloor finish liquid.

FIG. 2 is a depiction of a reverse view of an embodiment of the backpack of FIG. 1.

FIG. 3 is a depiction of an embodiment of the back pack of FIG. 1 with amovable lid or opening adapted or positioned to reveal the floor finishcomposition or container supported by the support surface formed in theinterior the portable unit or back pack. The container can include aflexible or rotatable coupling and a conduit that can be in fluidcommunication with an application wand.

FIG. 4A is a depiction of an embodiment of the flexible couplingassembly that transfers liquid floor finish from the container to theconduit.

FIG. 4B is a depiction of an embodiment of the flexible couplingassembly including a filter.

FIG. 5 is a depiction of an embodiment of a station formed in the backpack housing or case used as a conduit restraint or holder to fix theconduit in predetermined position and to restrain the conduit frommotion during the application of the floor finish.

FIG. 6A is a depiction of an embodiment of the external shape of oneembodiment of a floor finish container showing a conduit installationsurface.

FIG. 6B is a depiction of an embodiment of a flexible containerincluding a part of the coupling.

FIG. 7A is a depiction of an embodiment of the application wand used inconjunction with the portable unit or back pack. The conduit arisingfrom the container of liquid floor finish material is coupled to aflexible conduit associated with the application wand that carries thefloor finish from the container conduit for a coupling to the applicatornozzle. The wand also acts as a carrier for the liquid floor finishmetering apparatus and the distribution pad.

FIG. 7B is a depiction of an embodiment of the application wand used inconjunction with the portable unit or back pack. A single conduit leadsfrom the container of liquid floor finish material and is coupled to theapplicator nozzle. The wand also acts as a carrier for the liquid floorfinish metering apparatus and the distribution pad.

FIG. 8 is a depiction of an embodiment of the distal end of theapplication wand. FIG. 8 protects the applicator metering apparatus andapplicator nozzle with an installed pad on an installation surfaceattached to the wand. In FIG. 8, one embodiment of the installation ofthe pad on the applicator surface-using pad pockets installed in the padis shown for attachment of the pad to the wand assembly.

FIGS. 9A and 9B are a depiction of an embodiment of the attachmentsurface and application surface of the pad. Such a pad can use a Velcrosurface for attachment to the wand assembly and, on the application orfloor finish distribution surface of the pad, the pad can use amicrofiber material installed into the application surface. Theinstalled microfiber surface characteristics can be used to evenlydistribute the floor finish on the resilient vinyl tile-flooring surfaceto form a thick resilient robust layer. The pad containing a reservoirincluding an internal polymeric open cell foam structure that can act tomaintain a supply of the floor finish for high solids add-on to thefloor surface.

FIG. 10 is a depiction of an embodiment of a cross-section of the pad ofthe invention.

DETAILED DISCUSSION OF THE INVENTION

The floor finish system of the invention involves a portable reservoirfor the floor finish such as a portable system adapted for a singleuser. Such a portable system can include a back pack system that canserve as a mounting location for a container of the high solids floorfinish of the invention. The portable reservoir or back pack and theincluded floor finish or floor finish container is fluidly connected toan application wand having a fluid conduit leading to a metering tip andapplicator pad. The application wand contains metering apparatus thatpermits the user to apply an appropriate amount of floor finish to theresilient vinyl floor surface. Such apparatus can be incorporated intothe handle used by the user of the application wand. In a preferredembodiment, the individual user of the system can apply, in a singleapplication of high solids floor finish, a thick robust layer of floorfinish on a floor surface.

The portable reservoir or back pack is equipped with attachmentapparatus appropriate for the use of the application personnel.Typically the back pack structure is worn by the application personnelusing a shoulder strap or harness configuration applied to the user'sback. The portable reservoir, however, can be used in a variety ofconfigurations including as a chest pack, as a “fanny pack,” or anyother configuration that can be supported by application personnelduring floor finish application operations. The back pack container canbe configured to enclose a flexible or rigid, inflexible containerfilled with an appropriate amount of high solids floor finish.

The portable reservoir or back pack should be configured such that itcan be easily used by the application personnel over an eight hourperiod (including multiple fillings or replacements of the floor finishmaterial) conveniently without fatigue. Accordingly, the filled portablereservoir or back pack preferably weighs no more than about 15 kg, butshould contain at least 5 liters of floor finish with a maximum capacityof up to about 15 liters. In an embodiment, the backpack can accommodatea container with a capacity of about 7 liters. The portable reservoir orback pack should be configured for easy refilling or access to theinterior of the back pack. Access can permit removal of empty containersof floor finish and the insertion of new filled containers. In oneembodiment, the back pack can simply be filled from a reservoir of floorfinish without a separate container structure. However, preferably, theback pack is configured to receive and support a container of floorfinish. Preferably, the floor finish container is a flexible container,a semi-rigid container, or a rigid container, each of which can beadapted to the interior space of the back pack. In an embodiment, thefloor finish container is a collapsible polymeric bag made of two ormore layers. The container is simply inserted into the back pack withoutsignificant modifications to the back pack structure. However, in apreferred embodiment, the back pack contains interior access having aclosure structure that can be opened and closed during operations inwhich the empty containers are replaced by filled containers. In apreferred embodiment, an openable door or lid structure is installed inthe back pack exposing the interior of the back pack to easy access tothe empty containers and for insertion of a new filled container.

The interior of the portable reservoir or back pack is sized andconfigured for filling with liquid floor finish or configured to acceptand support the fluid floor finish container. In an embodiment, thecontainer has a “lock and key” structure such that only an appropriatelyshaped floor finish container can be effectively inserted into therecess within the back pack that can accept and support the back packcontainer. The surface of the container that contacts the portablereservoir or back pack wall or support surfaces preferably has a uniqueprofile such that only containers adapted to that profile will fit theinterior space of the portable reservoir or back pack. The container canhave a unique surface that comes into contact with the support structurein the back pack or can have a unique surface on the side of thecontainer that comes into contact with the interior space of the backpack. Such profiles can include protruding areas, indents, or an overallshape or profile adapted to the interior space of the back pack.Depending on application, the back pack can be configured to include twoor more separate containers that can contain either the identical floorfinish composition, combinable two-part floor finish compositions ordifferent floor finish compositions, depending on application.

The portable liquid floor finish system of the invention includes aconduit that can act as an apparatus of fluid communication directingthe floor finish from the back pack to the wand used to apply the floorfinish. In an embodiment, the a coupling is installed in the floorfinish container that directs the floor finish from the container to theattached to conduit structure. In an embodiment, a single conduit orhose couples to the source of liquid floor finish and to the meteringapparatus. In an embodiment, the conduit of the back pack is coupled toa conduit installed on the application wand in conjunction with themetering valve and pad.

The back pack can be adapted for use by both right handed and lefthanded individuals and for right handed and left handed use regardlessof the handedness of the individual. The conduit leaving the back packcan be installed in a right aspect or a left aspect using a conduitrestraint structure formed in the portable liquid floor finish systemfor ease of use and application in all environments by all users. In anembodiment, the container is permanently installed with the conduit andwhen the container and conduit is installed in the back pack with afresh amount of high solids floor finish, the conduit is directed fromthe container. In an embodiment, the conduit is coupled at its distalend to the metering apparatus and, proximal to that, coupled to thewand, and includes at its proximal end apparatus for mating with afitting on the container of floor finish. The conduit leading from thecoupling can be placed in a conduit restraint formed in the back packcase that prevents the two from undesirable or inappropriate motion.

In an embodiment, the container is coupled to the conduit employing atwo part coupling. One part of the coupling can reside on the conduit,to which it can be reversibly coupled. Another part of the coupling canbe an integral portion of the container, or can be coupled to thecontainer by the user. The two parts of the coupling can be threaded toreversibly couple to one another. In an embodiment, the container partof the coupling can include a filter. The filter can be oriented to bewithin the container in a configuration in which fluid leaving thecontainer must pass through the filter. The filter can have any of avariety of configurations. For example, the filter can be shaped like acylinder with a flattened end, like a sock or bag, cylindrical, tubular,bulbous, spherical, oblate, or the like. The filter can be coupled tothe coupling by any of a variety of suitable methods. For example, thefilter can be attached to the coupling by ultrasonic welding, friction,adhesive. The filter can be an integral part of the coupling.

Preferably, the filter is an elongated filter element that is resilientbut not floppy. That is, fluid or solids within the container cannotcrumple the resilient filter onto the opening that provides fluidcommunication with the conduit. A resilient filter can bend ifinstallation of a flexible container in the back pack urges the filterinto contact with the back pack. Preferably, the resilient filter isconfigured to reduce or avoid excess wear on a flexible container, forexample, by having rounded rather than pointed edges. The filter can bemade of any of a variety of materials suitable for making filters forfloor finish materials. For example, the filter can be plastic, metal,or non-woven material. By way of further example, the filter can be amesh, a mesh-like material, or a solid sheet with apertures.

The filter can include any size aperture or pore suitable for allowingfloor finish fluid to flow through the filter while retaining unwantedsolid, gel, or particulate matter. In an embodiment, the filterapertures have a maximum dimension of 0.015 inches to 0.2 inches. In anembodiment, the filter apertures have a maximum dimension of 0.03 inchesto 0.1 inches. In an embodiment, the filter apertures have a maximumdimension of 0.04 inches to 0.07 inches. In an embodiment, the filterapertures have a maximum dimension of 0.05 inches.

In an embodiment, the coupling includes a valve. The valve retains fluidin the container when the container is not coupled to the conduit. Forexample, the container part of the coupling can include a valve that isnormally closed. The conduit part of the coupling can include apparatusfor actuating the valve so that when the conduit is coupled to thecontainer, the container and the conduit are in fluid communication.

In an embodiment, once installed in the back pack, the container conduitis in turn connected to a conduit installed on the application wand thatleads directly to the application metering valve structure. Thecontainer conduit can be joined with the wand conduit using commonjoining apparatus including a connector or coupling providing fluidcommunication from the container to the wand floor finish applicationapparatus. In an embodiment, a single conduit leads from container tometering structure.

The conduit leading to the metering structure is preferably sized andconfigured to ensure that the application wand can direct a substantialquantity of liquid floor finish onto the floor. For preferredoperations, the back pack is structured and adapted to apply about 10milliliters to about 120 milliliters of floor finish per square meter offloor, preferably about 30 milliliters to about 100 milliliters of floorfinish per square meter of floor. Such an add-on will ensure a thick,resilient and robust coating on the floor surface. Such an add-on amountwill obtain, in a single dried application layer, a layer thickness,after evaporation of the liquid carrier fluid, that ranges from about0.01 to about 0.03 millimeters, preferably about 0.005 to about 0.05millimeters. The floor finish structure of the invention is adapted topermit the relatively rapid application of floor finish to the resilientvinyl floor surface. Accordingly, during preferred operations, a skilledapplicator can apply the desired amount and thickness of the floorfinish at a rate of about 3.0 to about 10 square meters per minute ofoperation.

The application wand of the invention is adapted for easy metering of anappropriate amount of the floor finish to the resilient vinyl floorsurface and to distribute the aqueous finish in an appropriate thincontinuous layer. In a preferred embodiment, the wand has, on a proximalend a handle and on a distal end attachment apparatus for theapplication pad. Proximate to the application pad is installed ametering valve or orifice that is connected to triggering apparatus inthe handle of the wand. The wand additionally includes a conduit thatcan provide fluid communication for the liquid floor finish from theback pack container or reservoir to the metering orifice proximate thepad. In a preferred mode, the application personnel will trigger theflow of floor finish until an appropriate amount is applied to the floorproximate the pad by manipulation on the application apparatus installedin the handle structure. The pad then is used to first acquire withinthe pad interior foam reservoir, an amount of the floor finish. Oncesubstantially saturated with liquid floor finish, the pad is then workedacross the floor surface to evenly distribute the floor finish in athick layer. The pad can be worked in a variety of patterns along thefloor surface. The pattern selected can be appropriate for the personneland for the space involved. For example, relatively narrow hallways canbe serviced by a linear back-and-forth application, however, largesquare areas can also be worked by an arc-like or semicircular-likeapplication pattern. However, the preferred mode involves theapplication of a sufficient amount of floor finish since that a thickresilient robust coating is formed in a single application on the floorsurface.

The proximal end of the floor application wand typically contains ahandle and a triggering apparatus to apply the floor finish, virtuallyany type of apparatus to meter or apply the floor finish can be used inthe handle. Common lever or trigger structures that are operablyconnected to the application nozzle can be used. The structure selectedpreferably can be easily adapted to the application of the appropriateamount of floor finish to the floor surface. The application wandtypically includes a conduit that passes from the back pack along orwithin the handle leading down to the application nozzle. In anembodiment, the conduit leaves the back pack, is then connected to theconduit in the wand using a coupling conveniently placed for easyattachment to the conduit on the handle. The conduit is then directed tothe metering structure. In an embodiment, a single conduit extends fromback pack to wand to metering apparatus.

The conduit can be mechanically associated with the wand in a variety ofways. The conduit can be installed within the tubular wand structure,can be attached along the exterior length of the structure usingmechanical fasteners or the conduit can be wound around the wand tomaintain a loose association of the conduit and the wand. The conduittypically ends at a metering structure installed at the distal end ofthe metering wand. The metering structure is typically installed on thedistal end of the application wand such that the liquid floor finish canbe applied without substantial splashing. The metering structure isoperably connected to the handle application apparatus for theappropriate application of the aqueous floor finish. The meteringstructure can include any valve-like structures for the measuredapplication of the appropriate amounts of floor finish. In a preferredembodiment of the invention the desired volume of floor finish can beselected by actuating the metering structure, which can include simpleon/off valves, mechanically or electrically driven valves or otherstructure.

One aspect of the metering structure involves the diameter of the outputorifice that is used to meter the appropriate volume of floor finish.The output metering structure typically has a diameter of about 0.05 to0.1 millimeters, preferably about 0.03 to 0.2 millimeters forappropriate add-on of floor finish. The application wand terminates atits distal end with an application pad. The application pad is installedin an articulating position at the end of the application pad to providerotation about to the end of the wand to maintain contact between theapplication surface of the pad and floor surface. Such an articulatingposition can be achieved by the use of a flexible linkage that ensuresthat the pad is in contact with the floor over the entire applicationsurface of the pad. A variety of structures can be used to attach thepad in a flexible articulated manner to the distal end of theapplication wand.

The application pad of the invention is adapted to be easily installedonto the distal end of the application wand, to act as a reservoir for asignificant proportion of the liquid floor finish and to have anappropriate surface area to distribute the liquid floor finish acrossthe floor in appropriate amounts such that the floor finish can beapplied at a single application to result in a thick robust continuousfloor coating.

One aspect of the pad is its ease of use. The movement of the padpreferably provides as little resistance to the application of the floorfinish as possible for the convenience and comfort of the individualusing the floor finish application system. Accordingly, the padpreferably can be sized and configured such that the resistance tomovement of the pad with the fluid floor finish across the floor isminimized. Such a pad will be easy to use, will apply floor finish inthe appropriate amounts but not result in substantial fatigue toapplication personnel that would interfere with the appropriate add-onamount of floor finish. In our work, we have found that a pad having anapplication surface that ranges from about 500 to about 2000 squarecentimeters provides an appropriate application surface that results ina high quality floor finish and minimum fatigue in the applicationpersonnel. The profile of the application surface can be generallyrectangular, oval, circular or other appropriate structure. In apreferred mode, we have found that the preferred pad is a generallyrectangular pad wherein the length of the pad is generally 2 to 6 timesthe width of the pad. Preferred pads have a dimension of about 10 toabout 20 centimeters in width and about 50 to 100 centimeters in length.The pad can be attached to the distribution wand using a variety oftechniques. The pad can have pockets or inserts installed in theattachment surface of the pad which can interact with mechanical deviceson the wand to ensure a close fitting association with the wandstructure. In one embodiment, the wand can have a flexible structurethat can be inserted into pockets formed in the pad that can be used toattach the pad to the wand. In an alternative embodiment, the pad canhave an attachment surface having a Velcro structure that can simply bepressed against the corresponding surface at the distal end of theapplication wand for reliable installation. The application padtypically includes the attachment surface, an internal foam reservoirand on the surface opposite the attachment surface, an application witha microfiber distribution structure.

The pad is typically manufactured by loosely assembling the attachmentsurface, the interior foam pad and the microfiber application surfaceand then mechanically attaching the layers one to the other in alaminate structure. A variety of attachment apparatus can be usedincluding hot melt adhesives, hot line lamination or sewing. In apreferred mode, the layers are assembled by sewing the pad along itslength and along its perimeter to ensure close association with thelayers.

The application surface has an installed microfiber distributionapparatus. The use of microfibers on the application surface ensuresthat the foam reservoir, the applied floor finish and the applicationsurface cooperate to apply a large quantity of the floor finish to thesurface resulting in the robust floor finish layer. The microfibers areinstalled in the pad with a preferred alignment. The microfibers aretypically placed in or installed in a pad support structure a directionthat is substantially normal to the surface of the pad. In other words,as the pad is moved across the floor, the microfibers are substantiallyperpendicular to the floor surface. It should be understood that,however, the microfibers are highly flexible and will move in accordancewith the net force applied by the application personnel. Accordingly,the microfibers will contact the floor finish and the floor surfaceduring application and will be moved in accordance with the motion ofthe pad. However, the microfibers are substantially installed in the padsurface in a direction normal to the pad surface (and the floorsurface). In a preferred mode, the microfibers are manufactured byinstalling the microfibers into a woven fabric by simply looping andknotting the microfiber into the fabric surface. The microfibers extendfrom the pad surface for a distance of about 0.1 to about 5 millimeters,typically about 0.1 to about 2 millimeters. About 50 to about 80% of thearea microfibers per square centimeter of the pad surface asmicrofibers, preferably about 70 to about 80% fibers per squarecentimeter for easy, low force but high add-on application of the floorfinish materials.

The internal foam reservoir formed within the application pad of theinvention can typically contain about 30 to about 85 milliliters offloor finish per square meter of pad. The pad is typically a small opencelled foam structure, having a thickness, before compression duringmanufacturing that can range from about 0.2 to about 2 centimeter inthickness.

The microfiber systems are small fibers having a dimension of about 0.2to about 5 denier, typically about 0.8 to about 1.5 denier. Themicrofibers are typically made from two relatively incompatible polymermaterials, for example, polyester and polyamide. The fibers arecoextruded and then split into microfilaments during manufacturing. Themost common structure of the microfiber is a core structure with wedgeshaped perimeter structures having a small, less than 0.5 denier aspect.The yarn made from the microfiber contains high surface area wedgeshaped filaments and a core filament. The capillary effect between thewedge shaped filament and the core filament creates a very highabsorbency which, in turn, permits the microfiber structures to absorblarge amounts of floor finish and enables the pad to apply large amountsof floor finish to the floor with a quality finish having little or nodefects in the finish surface. The preferred microfiber includes about80% polyethylene terephthalate polyester and about 20% polyamide such asa nylon.

The high solids floor finish compositions of the invention that can beused with the microfiber pad technology typically are formulated usingan aqueous material in a dispersion or suspension form. Typically, theaqueous floor finish includes an organic polymeric material augmentedusing a variety of other polymeric materials or additive compositions.Typically finish compositions are formulations that can includewater-formulated coatings including aqueous polish compositions ineither buffable, self polishing or non-buffable types, temporaryprotective coatings, or other well-known formulations types. Theseaqueous coatings can result in a substantially transparent coating aftervolatilization of the aqueous media. The formulations can includenon-volatile, solid film forming polymeric materials dispersed in theaqueous media using dispersing or emulsifying materials to form auniform aqueous formulation. Such emulsifier or dispersant materialsincluding anionic or nonionic agents are used in sufficient amounts toform a stable aqueous dispersion of the film forming polymeric materialsin the aqueous media. Judicious formulation of such film formingmaterials at high solids content, permits the application of sufficientamounts of the film forming polymer to permit the formation of a thickrobust coating in one application or pass. Such formulations can containother components of organic or inorganic character in polymeric or nonpolymeric forms. Such floor finishes can contain a plasticizer, asurfactant (wetting agent) or other additive material that facilitatesthe formation of a single smooth continuous floor finish layer. The filmforming polymer material generally includes a solid polymeric materialthat can be emulsified or dispersed in an aqueous media in combinationwith a wax or other polymer film formers, natural and synthetic resinsincluding alkali soluble resins and other additive materials.

Representative examples and suitable natural and synthetic polymermaterials include polymers including vinyl acetate, polymers includingvinyl chloride or vinylidene chloride, polyurethane materials,copolymeric materials including butadiene, acrylonitrile, styrene, vinylacetate, acrylic monomers, and in particular cross-linked acrylicsystems including metal complexed or ionic cross-linked acrylicpolymers. Other resins can include terpene materials, terpene-phenolicpolymers and others. Representative examples of commercially availablepolymeric floor finish the materials can be obtained from Rhom & Haas orSC Johnson Co.

Floor finish formulations of the invention can be manufactured bycombining the film forming polymer with an additive package including aplasticizer material. Both permanent and fugitive plasticizers can beincorporated for many applications. Representative examples of fugitiveplasticizers are diethylene glycol (carbitol materials), ethyleneglycol, ethylene glycol alkyl ether, benzyl alcohol and ethers thereof,and other such liquid materials. Permanent plasticizer materials includephthalate plasticizers, fatty acid esters of polyols, benzoate esters,tricresyl phosphate, and others. Plasticizers selected for use informulations of the invention are chosen in accordance withcompatibility and efficiency of introducing the floor finishes of theinvention at application temperatures.

Additive materials can also be used in the finish compositions in theinvention. Such additives commonly include surfactant a wetting agentcompositions. Other additive is can include preservatives, sanitizers,and I forming agents, preservatives, fragrances, pigments or dyes,leveling agents and other non additives.

An aspect of the floor finish formulations of the invention relates tothe amounts of materials present in the floor finish. Preferredcompositions can be formulated by combining aqueous preparations of thefilm forming polymer material, additives, another for acrylicingredients. The total amount of each material in the aqueous solutionis adjusted to provide from about 28 to 45 wt %, preferably 30 to 40 wt% total solids based on the floor finish composition taken as a whole.

A preferred useful formulation for use in the floor finish systems ofthe invention is as follows: TABLE Ultra High Solids Finish GeneralDescription Range Water 0-20% Fluorocarbon wetting agent 0.02-0.2%Silicone defoamer 0.02-0.2% Glycol ether 5-9% Tributoxyethyl phosphate2-5% Preservative 0.1-1% Surfactant 0-2% Polyacrylate emulsion (38%)55-75% Resin 0-7% Polyethylene/polypropylene wax (30-40%) 5-15%

DETAILED DESCRIPTION OF THE DRAWINGS

The invention uses a portable application system such as a back packcontainer for the floor finish. Such container is fluidly communicatedto an applicator wand through a conduit. The applicator wand includes avalve that can help to meter the floor finish onto the floor, through ametering nozzle, a distribution pad and a floor finish conduit. Thefollowing Figures detail the mechanical aspects of the floor finishapplication equipment of the invention. Within the Figures commonnumbering is used for identical elements in the Figures.

FIG. 1 is a depiction of an embodiment of a portable unit of theinvention including a back pack of the invention. The back pack 100includes a case 102 and a movable or openable lid 101 that can be openedto install or remove a floor finish container (not shown, see FIGS. 3and 6). The floor finish container can include a fitting that can befluidly coupled to a conduit 103 which can provide a pathway for thefloor finish liquid. In the operation of the back pack, the lid 101 isopened to reveal either a space for the installation of a container orthe installed container in place inside the back pack. The container iseither introduced or replaced with fresh finish containing material. Theconduit is coupled to the container, and the backpack is closed.

FIG. 2 is a depiction of an embodiment of the reverse side of the backpack 101 of the invention. In FIG. 2 is shown the closed opening 101 andthe case 102. The conduit 103 is shown extending from the edge of thecase 102. On the reverse side of the case 102 of the invention is shownrecess or indentation supports 104 a and 104 b formed in the case tosupport the introduction of the floor finish container (not shown, seeFIGS. 3 and 6) into case 102. The case 102 is manufactured preferablyfrom a thermoplastic material that can be made with predetermined moldedsupport surfaces for the container. Indents 104 a and 104 b provide botha lock and key security feature and to support the filled container ofliquid floor finish.

FIG. 3 is a depiction of an embodiment of the opened back pack of theinvention. In FIG. 3, the opening 101 is shown in an open position (notnecessarily fully opened). The container 106 is shown inserted into thecontainer or case 102. The container 106 is supported within the case102 by support surface 105 a and other support surfaces within themolded placement for the container 106 within case 102. The container isequipped with a coupling structure 107 a and 107 b that permits theconduit 103 to conduct floor finish from container 106 to theapplication wand (not shown). The conduit 103 is held in place in theback pack 102 by conduit restraint 108 that restrains the conduit inplace in the back pack during operation. The back pack 100 is adaptedfor use by left handed or right handed application personnel by forminga conduit restraint 108 on either side of the back pack (both left andright). The back pack is adapted for easy replacement of container 106by unattaching the conduit 103 from the container and simply removingcontainer 106 from the case 102 taking care to remove and install thecontainer 106 without damage to the coupling 107 a and 107 b.

FIG. 4A is a close up view depicting an embodiment of the coupling 107 aand 107 b, attached to the container 106 and installed in the supportstructure 105 a and 105 b. The fluid coupling 107 a and 107 b for fluidcommunication of the floor finish from container 106 to conduit 104 isaccomplished using a two part coupling structure. The coupling structureincludes a rotary cap 107 a and a container aperture device 107 b withmounting rings 108 a and 108 b. In an embodiment, when the container 106is installed in the back pack 102 on the support surface 105 b, thecontainer aperture device is installed into an opening 105 a that isgripped by the rings 108 a and 108 b of the container aperture device107 b. The ring structure 108 a and 108 b of aperture device 107 bmaintains the container 106 fixedly in place in the back pack 102. Thecontainer aperture device provides fluid communication from thecontainer through the aperture 107 b to the rotary cap 107 a and thehigh solids floor finish readily passes from the container through theaperture into the rotary cap and then through the conduit 103 to theapplication wand (not shown). In FIG. 4, ring 108 a and ring 108 b forma gripping surface that grips opening 105 a to maintain the container inposition.

FIG. 4B illustrates an embodiment of coupling 107 b. This embodiment ofcoupling 107 b can be an integral part of container 106. This embodimentof coupling 107 b includes rings 108 a and 108 b and also filter 200. Inan embodiment in which coupling 107 b is an integral part of container106, container 106 can form all or part of, or substitute for, ring 108b. Filter 200 as illustrated can be an elongated sock-like structurewith proximal end 202 and distal end 204. In an operationalconfiguration, filter 200 resides in container 106. Proximal end 202 canbe coupled to coupling 107 b surrounding opening 206 (not shown) definedby coupling 107 b. In this Figure, distal end 204 of filter 200 is shownsealed in a flattened configuration. Coupling 107 b includes thread 208for reversibly coupling to coupling 107 a. Fluid leaving container 106preferably passes through filter 200.

FIG. 5 shows details of an embodiment of the conduit restraint system.The restraint system includes edges 109 a and 109 b, indentation 110 andsurface 111 formed back pack 102. In the embodiment shown in FIG. 3, theback pack 102 includes a conduit restraint in both the left hand andright hand aspect of back pack 102. A recess 110 provides a location forthe conduit of the invention while restraint edges 109 a and 109 bmaintain the conduit against the recess 110. The profile of surface 111in the molded portion of the back pack 102 provides a location for theconduit 104 that ensures the conduit is not bent to obstruct flow of thefloor finish. In an embodiment, the container restraint structurecompresses the hose or conduit by about 5% or less to ensure that thehose or conduit is restrained by the structure.

FIG. 6A is a depiction of an embodiment of the floor finish container106 of the invention. In this embodiment, the floor finish container 106a is adapted to closely fit the internal space within the case 102. Theexternal surfaces of the container 106 a are complementary to the insidesurfaces of the case 102. In particular, surface 114 and 113 are adaptedfor the support structures or surfaces 105 formed in the case thatclosely fit the container 106 a to ensure that the container is wellmaintained within the case during application of the floor finish. Thecontainer has a coupling attachment surface 112 that provides a locationfor the installation of the coupling device 107 a and 107 b for theconduit 104.

FIG. 6B is a depiction of an embodiment of the floor finish container106 of the invention. In this embodiment, the floor finish container 106b is a flexible container that can fit in and conform to the internalspace within the case 102. Container 106 b includes an integral couplingdevice 107 b which can couple to coupling device 107 a, which can be onan end of the conduit 103. Coupling device 107 b can include filter 200(not shown). The flexible container can be a collapsible bag. Thecollapsible bag can include two or more layers of polymeric material.The inner lay is selected for compatibility with the floor finishcomposition. The outer layer can be selected to be an oxygen barrier.For example, the outer layer can be a polymer through which oxygenpasses only slowly or not at all, such as known ethylene vinyl alcoholcopolymers (e.g., EVOH).

FIG. 7A is a detail depiction of an embodiment of application wand 119 aof the invention. In this embodiment, the coupling device 107 a and 107b are installed onto the container 106 (not shown) within the back packof the invention. The conduit 103 extends to a coupling 115 that fluidlycouples a flow of the floor finish to a hose 117 that conducts the floorfinish to the applicator nozzle metering port 118. The handle 116 isinstalled with a trigger 116 a that is adapted to trigger a release ofthe floor finish from the metering port 118 to ensure that a substantialproportion of the high solids floor finish is applied to the floor fordistribution.

FIG. 7B is a detail depiction of an embodiment of application wand 119 bof the invention. In this embodiment, the coupling device 107 a can beinstalled onto the container 106 b (not shown) within the back pack 102of the invention. The conduit 103 conducts the floor finish to theapplicator nozzle metering port 118. The handle 116 is installed with atrigger 116 a that is adapted to trigger a release of the floor finishfrom the metering port 118 to ensure that a substantial proportion ofthe high solids floor finish is applied to the floor for distribution.

FIG. 8 is an embodiment of the distal, applicator portion of wand of theinvention. In FIG. 8 is shown the wand having installed on the wand 119a metering port 118 an applicator nozzle 120. Floor finish is deliveredto the application nozzle 120 through conduit 117. When the flow of thefinish is triggered by trigger 116 a (not shown), a volume of the floorfinish is released through nozzle 120 onto the floor. The liquid is thendistributed by the pad. The applicator pad 123 is installed onto a padattachment 122 that provides a support surface for the pad 123. In thisembodiment, the opposite ends of the attachment 122 are placed intopockets 124 formed in the pad 123 that maintains the pad on an installedposition on the attachment 122 of the wand structures 119.

FIGS. 9A and 9B show an alternative embodiment of pad 123 involving aVelcro attachment. In FIG. 9A, the pad Velcro surface 125 is shown. TheVelcro surface is sewn to the microfiber surface (see FIG. 9B) using asewn attachment 128 and sewn perimeter 126. FIG. 9B shows the microfibersurface 127 having a distribution of microfibers installed into a wovenor non-woven fabric used for floor finish distribution. Positionedbetween the Velcro attachment surface 125 and the microfiber surface 127is a foam reservoir (not shown) having an internal volume sufficient tomaintain a volume of the liquid floor finish.

FIG. 10 is a depiction of an embodiment of a cross-section of the pad ofthe invention. In FIG. 10 is shown in the microfiber surface 127, theVelcro attachment surface 125, the internal foam reservoir section 129that are all assembled using the stitched assembly structure 128.

EXPERIMENTAL Example 1

Using the portable floor finish unit shown in the Figures, an aqueousfloor finish composition: General Description Range Water, soft 8.15Zonyl FSJ 0.05 SWS 211 0.03 Diethylene glycol methyl ether 6.00 Texanol1.50 KP-140 1.20 Kathon CG/ICP 0.07 Rhopex B-1162 (Rohm & Haas) 68.00Conrez 500 (25%) 4.00 AC-325 (35%) 5.00 AC-540 (40%) 6.00 TOTAL 100.00was applied to a resilient vinyl floor, in one application, at an add onamount of about 3.8 liters (1 gallon) per each 30 m² (about 1000 ft²).The applied aqueous material was allowed to dry to a glossy film havinga thickness of about 0.01 mm.

Example 2

Using the portable floor finish unit shown in the Figures, an aqueousfloor finish composition: General Description Range Water, soft 16.25Zonyl FSJ 0.05 SWS 211 0.03 Diethylene glycol ethyl ether 5.40Dipropylene glycol methyl ether 1.50 KP-140 1.70 Kathon CG/ICP 0.07MorGlo 2 (Omnova) 60.00 Conrez 500 (25%) 6.00 AC-325 (35% 4.00 AC-540(40%) 5.00 TOTAL 100.00was applied to a resilient vinyl floor, in one application, at an add onamount of about 3.8 liters (1 gallon) per each 30 m² (about 1000 ft²).The applied aqueous material was allowed to dry to a glossy film havinga thickness of about 0.03 mm.

It should be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a composition containing “a compound” includes a mixture oftwo or more compounds. It should also be noted that the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

It should also be noted that, as used in this specification and theappended claims, the phrase “adapted and configured” describes a system,apparatus, or other structure that is constructed or configured toperform a particular task or adopt a particular configuration to. Thephrase “adapted and configured” can be used interchangeably with othersimilar phrases such as arranged and configured, constructed andarranged, adapted, constructed, manufactured and arranged, and the like.

Certain structures, materials of construction or claim elements havebeen described using a set of nomenclature consistent with thedescription of the invention. While the nomenclature using thisapplication is adequate for the description found herein, thedescription includes alternative language or synonyms that can also usedto describe the structures materials of construction or claim elements.Simply substituting a synonym is not resolve the use of this structurein infringement mode.

While embodiments of this invention as described in this specificationdrawings are fully capable of applying the sufficient liquid floorfinish in one application to form a thick robust floor finish, andachieve all the purposes object and aspect of the invention desired, theinvention is not limited solely to the structures described in theinvention disclosure and drawings that are provided for illustrationpurposes. As such, the invention is found in the claims hereinafterappended.

1. A method of forming a floor finish layer on the resilient vinylfloor, the method comprising: (a) applying an aqueous floor finishcomposition to a resilient vinyl floor, the floor finish compositioncomprising greater than about 30 wt.-% solids, at a rate of addition offloor finish of about 30 to 90 milliliters of aqueous floor finish pereach square meter of the floor; and (b) forming a substantial uniformdried floor finish layer having a thickness of about 0.01 to 0.03 mm andabout 10 to 35 gm-m⁻² of dried floor finish on the resilient vinylfloor.
 2. The method of claim 1, further comprising filtering the floorfinishing composition before applying it to the floor.
 3. The method ofclaim 1, further comprising: retaining the fluid in a containercomprising a normally-closed valved coupling; opening the valve bycoupling the container to a conduit that provides fluid communication tothe floor; and passing fluid through the coupling.
 4. The method ofclaim 3, further comprising filtering the fluid before it passes throughthe coupling.
 5. The method of claim 1 wherein the dried floor finishlayer comprises about 15 to 30 gm-m⁻².
 6. The method of claim 4 whereinthe floor finish layer comprises a layer formed by a single applicationof the liquid floor finish material.
 7. The method of claim 1 whereinthe floor finish is applied by metering about 35 to 80 milliliters ofaqueous floor finish onto a floor surface and distributing the aqueousfloor finish using the microfiber pad, wherein the application anddistribution step are repeated at least once.
 8. The method of claim 1wherein the floor finish is applied from a portable unit that isreplenished with aqueous floor finish.
 9. The method of claim 8 whereinthe portable unit comprises a back pack configured to contain 5 to 15liters of floor finish.
 10. A system capable of forming a floor finishlayer on a resilient vinyl floor, the system comprising: (a) a portablecontainer for liquid floor finish having a reservoir of about 5 to 20liters, the container comprising a coupling providing fluidcommunication to a wand applicator; (b) a wand applicator comprising ahandle, an applicator pad and a conduit providing fluid communication offloor finish from the container to the applicator pad; and (c) apparatusto meter about 30 to 90 milliliters of the aqueous floor finishcomposition onto each square meter of the resilient vinyl floor.
 11. Thesystem of claim 10 wherein the system of claim 10 wherein the portablecontainer comprises a backpack comprising a case adapted for supportinga container of liquid floor finish.
 12. The system of claim 10 whereinthe coupling comprises a rotary coupling.
 13. The system of claim 10,wherein the coupling comprises a filter adapted and configured to filterthe fluid before it enters the coupling or the conduit.
 14. The systemof claim 13, wherein the filter comprises a resilient, elongated filterelement.
 15. The system of claim 10, wherein the coupling comprises anormally closed valve and a valve actuator; the normally closed valvebeing adapted and configured to retain fluid in the container when thecontainer is not coupled to the conduit; the actuator being arranged andconfigured to open the valve upon coupling to the conduit.
 16. Thesystem of claim 10 wherein the handle comprises apparatus to meter theaqueous floor finish.
 17. The system of claim 10, wherein the containercomprises a flexible, collapsible bag; the bag comprising two polymericlayers; the outer lay being an oxygen barrier.
 18. The system of claim10 wherein the case comprises a hose restraint.
 19. A package suitablefor a liquid floor finish composition, comprising: a flexible containerdefining an aperture; a coupling filling the aperture and providing forfluid communication to surroundings of the container; the couplingcomprising a resilient, elongated filter element.
 20. The package ofclaim 20, wherein the coupling further comprises a normally closedvalve.